OBJECTIVES

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OBJECTIVES

• After studying Chapter 31, the reader will be
  able to
• Prepare for Engine Repair (A1) ASE certification
  test content area E (Fuel, Electrical,
  Ignition, and Exhaust System Inspection and
  Service).
• List the steps necessary to install and start-up
  a rebuilt engine.
• Discuss the importance of torquing all bolts or
  fasteners that connect accessories to the engine
  block.
• Describe what precautions must be taken to
  prevent damage to the engine when it is first
  started.
• Explain how to break-in a newly rebuilt engine.
• Describe how to replace a timing belt on an
  overhead camshaft engine.

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PREINSTALLATION CHECKLIST

• Before installing or starting a new or rebuilt
  engine in a vehicle, be sure all of the following
  items have been checked.
• Battery fully charged.
• Prelube the engine and check for proper oil
  pressure.
• Check that all of the vacuum lines are correctly
  installed and routed.
• Know the ignition timing specification and
  procedure.
• Check that fresh fuel is in the fuel tank.
• Be sure that the radiator has been tested, is
  free from leaks, and flows correctly.
• Check that all accessory drive belts are routed
  and tensioned correctly.

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PREINSTALLATION CHECKLIST
FIGURE 31-1 Prelubricating the engine is a very
important step that should be performed before
starting the engine. Notice that oil is flowing
through the pushrods, over the rocker arms, and
onto the valve springs.
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MANUAL TRANSMISSION INSTALLATION

• If the engine was removed with the transmission
  attached, the transmission should be reinstalled
  on the engine before other accessories are added.
  
• The flywheel is installed on the back of the
  crankshaft.
• The clutch is installed next. Usually, a new
  clutch is used at the least, a new clutch
  friction disk is installed.
• Finally, the engine bell housing is put on the
  engine, if it was not installed before.

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MANUAL TRANSMISSION INSTALLATION
FIGURE 31-2 Bell housing alignment dowel pins are
used to ensure proper alignment between the
engine block and the transmission.
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THE HEADLESS BOLT TRICK

• Sometimes parts do not seem to line up correctly.
  Try this tip the next time.
• Cut the head off of extra-long bolts that are of
  the same diameter and thread as those being used
  to retain the part, such as a transmission.

FIGURE 31-3 Headless long bolts can be used to
help install a transmission to the engine.
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AUTOMATIC TRANSMISSION INSTALLATION

• On engines equipped with automatic transmission,
  the drive plate is attached to the back of the
  crankshaft.
• The bell housing is part of the transmission case
  on most automatic transmissions.
• Usually, the torque converter will be installed
  on the transmission before the transmission is
  put on the engine.

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AUTOMATIC TRANSMISSION INSTALLATION
FIGURE 31-4 Typical automatic transmission torque
converter.
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STARTER

• It is generally easier to install the starter
  before the engine is put in the chassis.
• The starter should be checked to make sure that
  the starter drive pinion does not bind on the
  ring gear.

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ACCESSORIES

• All belt-driven engine accessories are mounted on
  the front of the engine.
• Some engines drive all these accessories with one
  belt.
• Other engines use as many as four belts.
• Install new spark plugs and spark plug wires.

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ENGINE INSTALLATION

• A sling, either a chain or lift cable, is
  attached to the manifold or head bolts on the top
  of the engine.
• A hoist is attached to the sling and snugged up
  to take the weight and to make sure that the
  engine is supported and balanced properly.

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ENGINE INSTALLATION

• The engine must be tipped as it was during
  removal to let the transmission go into the
  engine compartment first.
• The transmission is worked under the floor pan on
  rearwheel- drive vehicles as the engine is
  lowered into the engine compartment.
• The front engine mounts are aligned then the
  rear cross-member and rear engine mount are
  installed.
• The engine mount bolts are installed, and the
  nuts are torqued.
• Then the hoist is removed.

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COOLING SYSTEM

• The radiator is installed and secured in place,
  followed by the cooling fan and shroud.
• The fan and new drive belts are then installed
  and adjusted.
• New radiator hoses, including new heater hoses,
  should be installed.

FIGURE 31-5 Most engine rebuilders install a
temperature-sensitive device on the engine. These
sensors are used by the rebuilders for warranty
purposes to record any occurrence of engine
overheating. This small disk is glued to the
engine block and will pop out if the engine
overheats.
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FUEL AND EMISSION CONTROLS

• The carburetor (if the vehicle is so equipped)
  should be installed with a new gasket.
• The fuel and vacuum hoses should be inspected
  carefully and replaced as required.
• The fuel-injection system (if the vehicle is so
  equipped) should be carefully inspected for
  damage while it is off the engine and then
  reinstalled, being certain to follow recommended
  procedures and torque settings.
• The fuel and air filters should be replaced.

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ELECTRICAL SYSTEM

• Connect all wiring to the starter and generator
  (alternator) as required.
• Connect the instrument and computer sensor wires
  to the sensors on the engine.
• Check to make sure that the starter will crank
  the engine.

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ENGINE START

• The engine installation should be given one last
  inspection to ensure that everything has been put
  together correctly before the engine is started.
• If the engine overhaul and installation are done
  properly, the engine should crank and start on
  its own fully charged battery without the use of
  a fast charger or jumper battery.
• As soon as the engine starts and shows oil
  pressure, it should be brought up to a fast idle
  speed and kept there to ensure that the engine
  gets proper lubrication.

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ENGINE START

• After the engine has started, the following items
  should be checked
• Is the valve train quiet? Some engines will
  require several minutes to quiet down.
• Record the engine vacuum. It should be 17 to 21
  in. Hg at sea level.
• Check for any gasoline, coolant, or oil leaks.
  Stop the engine and repair the leaks as soon as
  possible.
• Check the charging system for proper operation.
  The charging voltage should be 13.5 to 15.0 volts.

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NORMAL OPERATING TEMPERATURE

• Normal operating temperature is the temperature
  at which the upper radiator hose is hot and
  pressurized.
• Another standard method used to determine when
  normal operating temperature is reached is to
  observe the operation of the electric cooling
  fan, when the vehicle is so equipped.

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HOW TO WARM UP A COLD ENGINE

• The greatest amount of engine wear occurs during
  start-up.
• The oil in a cold engine is thick, and it
  requires several seconds to reach all the moving
  parts of an engine.
• After the engine starts, the engine should not be
  raced, but rather allowed to idle at the normal
  fast idle speed as provided for by the choke fast
  idle cam (on carburetor-equipped engines) or by
  the computer-controlled speed on fuel-injected
  engines.

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BREAK-IN PRECAUTIONS

• Any engine overhaul represents many hours of work
  and a large financial investment.
• Precautions should be taken to protect the
  investment, including the following
• Never add cold water to the cooling system while
  the engine is running.
• Never lug any engine.
• Change the oil and filter at 500 miles (800
  kilometers) or after 20 hours of operation.
• Remember that the proper airfuel ratio is
  important to the proper operation and long life
  of any engine.
• Be certain to use spark plugs for the proper heat
  range.

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OIL CHANGE
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OIL CHANGE CONT
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OIL CHANGE CONT
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OIL CHANGE CONT
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WATER PUMP AND TIMING BELT REPLACEMENT
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WATER PUMP AND TIMING BELT REPLACEMENT CONT
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WATER PUMP AND TIMING BELT REPLACEMENT CONT
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SUMMARY

• Carefully install all accessories.
• When installing the transmission and other
  components on the engine block, be sure to use a
  torque wrench and tighten all fasteners to
  factory specifications.
• Always adjust the clutch free play before
  starting the engine.
• Temperature recording sensors should be installed
  on cylinder heads. This lets the rebuild
  technician know if the engine has been overheated.

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SUMMARY

• A new oxygen sensor(s) should be installed to
  ensure that the engine operation is within
  acceptable limits. If the oxygen sensor is
  defective, the engine may operate too lean. A
  lean-operating engine runs hotter than normal.
• Change the engine oil after 500 miles (800
  kilometers) or sooner, and use SAE 5W-30 or SAE
  10W-30 engine oil.

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REVIEW QUESTIONS

• How are the clutch and bell housing installed?
• What should be done to help prevent rear cylinder
  distortion when the bell housing is being
  installed on the engine?
• Describe the engine break-in procedure.

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CHAPTER QUIZ

• What can an engine rebuilder install that
  monitors if the engine has been overheated?
• A thermal disc
• A coolant leak detector
• An oil level gauge
• Either b or c

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CHAPTER QUIZ

• 2. If the bell housing is not properly torqued to
  the engine block, _____.
• The bell housing will distort
• The engine block will crack
• The rear cylinder can be distorted (become
  out-of-round)
• The crankshaft will crack

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CHAPTER QUIZ

• 3. Break-in engine oil is _____.
• Of the same viscosity and grade as that specified
  for normal engine operation
• SAE 40
• SAE 30
• SAE 20W-50

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CHAPTER QUIZ

• 4. Normal operating temperature is reached when
  _____.
• The radiator cap releases coolant into the
  overflow
• The upper radiator hose is hot and pressurized
• The electric cooling fan has cycled at least once
  (if the vehicle is so equipped)
• Both b and c occur

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CHAPTER QUIZ

• 5. Lugging an engine means _____.
• Wide-open throttle in low gear above 25 miles per
  hour
• That engine speed does not increase when the
  throttle is opened wider
• Starting a cold engine and allowing it to idle
  for longer than 5 minutes
• Both b and c

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CHAPTER QUIZ

• 6. Which computer sensor should be replaced if
  the engine had been found to have a defective
  head gasket or cracked head?
• Throttle position sensor
• Oxygen sensor
• Manifold absolute pressure sensor
• Engine coolant temperature sensor

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CHAPTER QUIZ

• 7. How should the vehicle be driven to best break
  in a newly overhauled engine?
• At steady and low speeds
• At varying speeds and loads
• At high speeds and heavy loads
• At idle speed and little or no load

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CHAPTER QUIZ

• 8. Normal operating temperature is achieved when
  _____?
• When heat comes from the heater
• When the cooling fan cycle
• When the engine exhaust gets hot
• When the lower radiator hose gets hot

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CHAPTER QUIZ

• 9. Pre-lubricating the engine should be done by
  using the starter motor to rotate the engine
  until oil pressure is displayed on a gauge.
• True
• False

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CHAPTER QUIZ

• 10. Why must an engine equipped with flat-bottom
  lifters be broken in at a fast idle?
• The camshaft in a cam-in-block engine is only
  lubricated by splash oil
• The flat-bottom lifters have to wear slightly
  concave in order to rotate
• Both a and b are correct
• Neither a nor b are correct

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• END